Method of making wrought iron



Dec. 13, 1932. wlLLE 7 1,890,660

METHOD OF MAKING WROUGHT IRON Filed Jan. 28, 1930 "I Sheets-Shet 1 CONVERTERS R l M @MM; M,MZW

Dec. 13, 1932. F. H. WILLE METHOD OF MAKING WROUGHT IRON Filed Jan. 28, 1950 7 Sheets-Sheet 2 M fi j iri INVENTOR Dec. 13, 1932. F. H. WILLE 1,890,560

METHOD OF MAKING WROUGHT IRON Filed Jan. 28, 1930 7 Sheets-Sheet 3 INVE NTOR Dec. 13,1932. F. H. WILLE METHOD OF MAKING WROUGHT IRON Filed Jan. 28, 1930 7 Sheets-Sheet 4 3 INVENTOR Zen 17% A24 Km & KM

Deg. 13, 1932.

F- H. WILLE METHOD MAKING WROUGHT IRON Filed Jan. 28, 1930 7 Sheets-Sheet 5 Dec. 13, 1932.

F. H. WILLE METHOD OF MAKING WROUGHT IRON Filed Jan. 28, 1930 '7 Sheets-Sheet 6 INVENTOR Patented Dec. 13, 1932 FEEDRIK H. WILLE, OF CHICAGO, ILLINOIS, ASSIGNOB TO A. III. BYERS COMPANY, OF PITTSBURGH, PENNSYLVANIA, A CORPORATION OF PENN$YLVANIA METHOD OF MAKING- WB-OUGI-IT IRON Application filed January 28, 1930. Serial No. 423,979.

My invention relates, in general, to the manufacture of wrought iron by the Aston process and, in particular, to methods of carrying out the operations necessary in the manufacture of wrought iron by this process.

The Aston process for the manufacture of wrought iron is now well known and, briefly, consists of pouring molten ferrous material into a slag bath so that the solidified or partly solidified granules of ferrous material formed during the pouring are individually coated with slag and welded together to form at the bottom of the slag receptacle a compressible mass or ball of Wrought iron. The ball thus formed can be compressed to form a bloom which may then be rolled or reduced to a billet or any other desired form.

In United States Patent No. 1,820,175, granted August 25, 1931, to my assignee as assignee of Addison H. Beale, there is explained the desirability of a receptacle of special shape for containing the slag into which the molten ferrous material is poured,

as well as of distributin the stream of ferrous material throughout the slag bath. In order to insure the uniform distribution of the molten ferrous material throughout the slag, and to avoid excessive heating of any one portion of the latter, I have devised an apparatus for automatically pouring molten ferrous material into a slag bath in such a manner that the desire-d result is obtained. Such apparatus is specifically described and claimed in my copending application Serial No. 537,856, filed May 16. 1931, which application is a division of this application. There has also been devised an arrangement of the equipment necessary in the manufacture of wrought iron by the Aston process so to facilitate the necessary operations and reduce the amount of time required for the completion thereof so that the process may be carried out more efiiciently and more expeditiously. Such arrangement is de-' scribed and claimed in the copending application of Herman A. Brassert, Serial No. (526.984. filed July 30, 1932.

There is provided a plant for the manufacture of wrought iron having one or more slag furnaces, a ball press, and one or more shotting machines therebetween. Each sho'tting machine preferably consists of a reciprocable platform carrying a table adapted for rotary movement. A tiltable ladle is supported on the table and means are provided for reciprocating the platform, rotating the table and tilting the ladle, all of said operations being preferably performed automatically. The reciprocable platform I is preferably supported by the beam of a platform scale so that the amount of ferrous material poured from each machine into a receptacle of slag positioned therebeneatli may be accurately determined. 7

In the plant arrangement previously mentioned, a track is provided to connect the slag furnace, shotting machines and ball press whereby cars carrying slag receptacles may be readily shifted from one point in the plant to another. Briefly, the arrangement is such that empty slag receptacle cars are positioned adjacent the slag furnace to receive a charge of slag. The cars are then positioned beneath the shotting machines which pour therequired amount of molten ferrous material into the slag and distribute it therethrough. From the shotting machines, the cars are shifted to the ball press where excess slag is decanted therefrom and the balls dumped adjacent the press for treatment therein. In order to increase the speed of production there are employed a plurality of shotting machines whereby several slag receptacle cars may simultaneously receive a charge of molten ferrous material into their respective slag contents.

The invention may be fully understood by reference to the accompanying drawings taken in connection with the following description, the drawings illustrating a present preferred embodiment of the invention which is nowise to limit the scope thereof as it is intended merely as an example.

- In the drawings: 7 a

Fig. 1 is a schematic diagramof a plant lay-out which I have provided for the rapid and efficient production of wrought iron by. the Aston process;

Fig. 2 is a plan view to enlarged scale of a portion of the lay-out shown in Fig. 1;

Fig. 3 is a sectional view through the plant at the plane of the line ITIIII of Fig. 2 showing parts in elevation;

Fig. 4 is a plan view of one of the shotting machines;

Fig. 5 is aside elevation thereof;

Figs. 6, 7 and 8 are diagrammatic views showing the path traversed by the stream of molten ferrous material as the shotting inachines pour their contents in to the slag baths in the slag receptacles.

Referring to the drawings wherein is shown a preferred form of the invention, Fig. 1 illustrates schematically a plant for the manufacture of wrought iron. The plant consists ofa slag furnace 20, a plurality of shotting machines 21 and a press 22. 1 The shotting machines 21 are mounted on a floor 23 above the floor level of ti e furnace and the press. Trains of slag receptacle cars 24 are adapted to be moved past the furnace,'the shotting machines and the press on a track 25 by meansof any suitable source of motive power.

In order to provide a convenient source of ferrous material, Bessemer converters or open-hearth furnaces are preferably installed in the locality indicated by the numeral 26. Appropriate crane facilities are provided for transferring the output of the ferrous material making equipment to the shotting machine ladles as is illustrated in greater detail in Fig. 3. A track 27 connects the ferrous material making equipment and the shotting machines to further aid the transfer of molten ferrous material to the ladles.

The shotting machines proper are illustrated in Figs. 2 to 5, Figs. 2'and 3 showing the general arrangement of the machines in the plant and Figs. 4 and 5 illustrating the details of their construction. In general, each shotting machine consists of a reciprocable platform '30, a table 31 adapted for rotary movement on the platform and a ladle 32tiltably' mounted on the table 31. The platform 30 has an opening 3O therein and is provided with wheels 33 which rest on rails 34 to permit reciprocation of the platform.

' The rails 34 are carried by the beam 35 of a platform scale having an indicating dial 36. Suitable stops 37 shown in Fig. 4limit'tl1e reciprocating movement of the platform 30. As shown in Fig. 2 the shotting machines 21 overlie openings 21 in the floor 23 and the rotary table 31 of each machine has a circular opening 31 therein ofthe same size as the opening 30 in the platform 30 so that it is possible, by tilting the ladle 32, to pour metal therefrom through the opening 31 in the table, the opening 30 in the platform 30,

and theopening 21 in the floor 23, into a receptacle beneath the machine.

The means for reciprocating the platform 30 includes an electric motor 37 and reduction gearing 38 which serves to connect the 40 and causes the motor 3'? to be reversed at the limits of movement of the platform 30 so as to prevent over-travel thereof and insure continuous reciprocation.

The platform 30 has a circular track 41 surrounding the opening 30' in the platform. The table 31 is provided with wheels 42 engaging the track 41 so that the table may be given a rotary movement with respect to the platform 30. Stops 43 prevent over-travel of the table and automatic means for oscillating the table on its track include a motor 44 and reduction gearing 45 connecting the motor to one of the wheels 42. A limit switch 46 is driven from the reduction gearing and reverses the motor 44 periodically so that the table 31 executes an oscillatory movement.

The ladle 32 has trunnions 50 in bearings 47 on the platform 31 which carries means for tilting the ladle 32 comprising a motor 48 and reduction gearing 49. A tilting shaft 51 is journalled in a housing 52 and carries a tilting gear 53 which is in mesh with the reduction gearing 49. A clutch 54 normally connects the tilting shaft 51 and one of the ladle trunnions 50. A limit switch 55 is driven by the reduction gearing 49 to prevent excessive tilting of the ladle 32.

The various reduction gears and the limit and reversing switches previously mentioned are well known devices and are not described in detail for that reason. The arrangement of the reduction gears is indicated on the drawings and will be obvious from an inspection thereof. The limit and reversing switches 39, 46 and 55 are arranged to be driven from their respective reduction gears 38, 45 and 49 at a speed such that the operations of the various members of the shotting machine will be properly coordinated. These arrangements, however, are subject to change depending upon the size of the charge and other factors. The stroke of the platform 30, the angular movement of the table 31 and the tilting movement of the ladle 32 may be adjusted to suit difierent sizes of receptacles and charges of different weights. Variations in the extent of movement of the shotting machine produce differentdistributions of the molten ferrous material in the slag bath 'as indicated diagrammatically in Figs. 6, 7 and 8 which will be mentioned further in the description of the operation of the structure described heretofore.

In describing the mode of operation of the apparatus, it'will first be assumed that a slag receptacle of the size and shape of that shown in Fig. 6 is placed on one of the cars 24 which is positioned beneath the floor 23 shown in Fig. 3. The shotting machine 21 will be assumed stationary in the position illustrated in this figure. Before a being placed beneath the shotting machine,- the slag receptacle is filled to the point indicated by the line with slag from the furnace 20. When the slag receptacle on the car 24 has been partly filled with slag and positioned beneath the shotting machine 21 as in Fig. 3,21. charge of molten ferrous material is transferred from the furnace or converter at 26 to the ladle 32 of the shotting machine by means of a pouring ladle 61 which. may be carried on ladle car 62 traversing the track 2'7. An over-head crane 63 picks up the pouring ladle 61 and pours its contents into the ladle 32.

The amount of ferrous material poured'into the ladle 32 is, of course,- registered on the dial 36 of the scale supporting the platform 30. The shotting machine is now ready for the commencement of its operation.

The operation of the shotting' machine is initiated by simultaneously starting the motors 37, arena 4:8. The starting and control circuits and devices for these motors are standard equipment and are not described in detail. When the motors 37, l i and 48 are started, the platform 30 is reciprocated on its wheels 33 along the rails 34. Simultaneously, the table 31- is oscillated on its wheels 42 resting on the track 41. A tilting movement is likewise imparted to the ladle 32 so that the latter reciprocates longitudinally with the platform 30, oscillates about the vertical axis of the table 31 and is tilted about its own horizontal axis. By properly adjusting the limit switches controlling the movement of the platform and table, the stream of molten ferrous material poured from the ladle 32 may be caused to trace the paths of different shapes. Examples of these paths are shown in Figs. 6, 7 and 8.

Referring particularly to Fig. 6, and assuming that the ladle 31 is tilted sufficiently to begin pouring when the platform 30 is at the extremity of its stroke, the stream of ferrous material from the ladle 32 will first strike the surface of the slag bath at the point 1 at the left-hand end of the slag receptacle shown in Fig. 6. The simultaneous reciprocation of the platform 30 and oscillation of the table 31 will cause the ferrous material stream to follow the path 111, etc., in the direction of the arrows. This movement of the ferrous material stream requires that the reversing switches for the reciprocating and oscillating motors be ad justed so that the table 31 executes two complete cycles of oscillation while the platform 30 moves from one end of its stroke to the other. The extremities of the stroke of the platform 30 are indicated by the dotted lines 64L and 65 in 3. On the return movement of the platform 30, the ferrous material stream traverses t-he path 2-'22, etc., shown in Fig. 6.

On the next outward movement of the platform, the ferrous material stream follows the path 3'-33, etc. This path is not identical with that of the first stroke, 11-1, etc., because of the fact that as the ladle 32 is tilted about its horizontal axis by the motor 48, the horizontal distance between the axis of the ladle trunnions and a vertical line passing through the point of contact of the ferrous material stream with the slag bath increases. This effect continues as the ladle is tilted further and prevents the ferrous material stream from retracing itspath on successive reciprocations of the platform 30. The dotted line 66 in Fig. 4 shows the path traversed by the ladle spout after the ladle has been tilted from its original vertical position. Tilting of the ladle thus causes a shift in the point of contact of the ferrous material stream with the surface of the slag bath.

After the ladle spout has moved vertically to a point below a horizontal plane containing the ladle trunnions, the horizontal distance between the axis of the trunnions and a vertical line passing through the point of contact of the ferrous material stream with the slag bath begins to decrease. The remaining portion of the path of contact of the ferrous material stream with the slag bath is indicated by numerals in Fig. 6, the pouring stopping at the point 10 at the left-hand end of the slag receptacle.

Fig. G illustrates the path followed bythe ferrous material stream in the manufacture of a 9600 pound ball, or, more properly. cake,

owing to its preferred form as shaped in the slagreceptacle. According to a preferred method, the control equipment for the shotting machine is arranged so that the platform makes one complete reciprocation forward and back in two minutes or a single stroke in one minute; The control equipment for the table is adjusted so that the latter makes four 90 oscillations in two complete cycles during one minute. At this adjustment, it is found that 9600 pounds of ferrous material may be poured into the slag bath in ten minutes. 7

For producing a 6000 pound ball, a slag receptacle having an outline such as that shown in Fig. 7 is employed and the control equip ment for the shotting machine is adjusted so that the table makes one and a half complete oscillation cycles or three 90 movepound ball. If the tilting speed of the ladle is such that the required weight of metal is poured in about six minutes, a satisfactory result will be obtained.

Fig. 8 is an illustration of the pouring path in the manufacture of a .4400 pound ball which can be effected in aboutfour and one-half minutes. In this case, the oscillations of the table are through an angle of only'and the stroke of the platform is determined by the lengthof the slag receptacle.

Since different amounts of metal are required for the formation of'balls of different weights, pouring will start at different points in'the tilting movement ofthe ladle in accordance with the amount of metal in the ladle. The ladle may be tilted to the pouring position befor the platform reciprocation and table oscillation are commenced in order to insure that the stream willstrike the slag bath surface at the same point in the beginning of each complete operation. The speed of tilting the ladle is preferably adjusted sothat the pouring rate is approximately 1000 pounds'per minute. At the beginning of the pour the slag receptacle is approximately half full-and at the end of the pour the slag and ball practically fill the receptacle to the top.

In apreferred embodiment of the invention, I have provided for amaximum travel of the platform of eight feet. When it is desired to manufacture balls of smaller sizes, however, the stroke of theplatform may be reduced by properly adjusting the limit and re versing switches. c r After the required amount of metal has been poured into the slag receptacle, the car 21 is shifted to the neighborhood of the press 22 at which'poiut the excess slag is decanted from the receptacle into an empty receptacle and the ball remaining in the first mentioned slag receptacle is then dumped at the press 22 for treatment therein. In the press 22, the ball is reduced to a bloom of'wrought iron which may then be given any desired treatment, such as rolling, to produce wrought iron articles. After the slag receptacles have been emptied of the excess slag and the ball, they are returned to the slag furnace 20 where they are partly refilled with slag and again passec under the shottmg machine to form ad- (lltYOllfil balls.

The movement of the shotting machines is,

of course, stopped before the slag receptacles are moved from under the machines. The ladle82 is restored to its vertical position for receiving another charge of ferrous metal from the pouring ladle 61 and the entire cycle of operations may then be repeated.

I'have thus provided apparatus for rapidly and eificiently carrying out the Aston process for the manufacture of wrought iron. The operations of the machines are largely automatic and a minimum ofmanual control is necessary. This makes it possible for a comparatively large installation to be controlled by few men with a resulting lowering in costs of production. The plant lay-out is such that the operation is of the line variety so that no unnecessary transportation of material in process is necessary.

The movement of the shotting machines is such as to secure a uniform distribution of the metal throughout the slag so that a superior quality of wrought iron is produced.

In the claims, the term continuously altering, as used with reference to the control of the relative movement of the slag bath and entering ferrousmaterial stream, comprehends such alteration as will present localized excess accumulationof the ferrous granules in the slag bat-h such as would occur with a discontinuous relative movement or other movement resulting in introducing the stream during a substantial period into a relatively localized portion of the bath.

Certain features not claimed herein are de scribed and claimed in said copending application of Herman A. Brassert and also in the copending application of James Aston and Herman A. Brassert, Serial No. 626,985, filed July 30, 1932, the copending application of James Aston and Edward B. Story, Serial No. 626,986, filed July 30, 1932, the copending application of Charles E. Gross, Serial No. 620,987, filed July 30, 1932, the co 1 ending application of James Aston and Edward B. Story, Serial No. 626,988, filed July 30, 1932, and the copending application of Edward 13. Story and William T. Case, Serial No. 628,- 125, filed August 10, 1932.

Although I have illustrated but a single preferred embodiment of my invention, 1 do not intended to be limited to the specific details thereof since the invention may be practiced in other forms. Minor changes and alterations will be apparent to those skilled in the art and all such changes may be made without departing from the invention as defined by the appended claims.

I claim: I

1. In a method of making wrought iron by pouring ferrous material into a slag bath, the steps comprising altering the relative po sitions of the pouring stream and bath to trace by the pouring stream a path on the bath surface, and then further altering the relative positions of the pouring stream and bath todeviate from said first mentioned path and traceby the pouring stream a different path on, the bath surface.

2. In the manufacture of wrought iron by the Aston process which comprises pouring ferrous material into a bath of molten slag, thesteps comprising supplying to a ladle the ferrous material to be poured and pouring such ferrous material from such ladle into a receptacle containing the bath of molten while relatively shifting th ladle and bath transversely and relatively turning the ladle and bath in a horizontal plane to assist in maintaining a proper temperature difference between the ferrous material poured in and the portion of the slag bath entered thereby and cause proper granulation of the ferrous material in the successive parts of the bath entered thereby.

3. In a method of making wrought iron by pouring molten ferrous material into a bath of relatively cool slag in a receptacle, the steps comprising substantially continuously altering the relative positions of the slag bath and entering ferrous material stream to distribute the entering stream over the maor portion of the bath surface to cause the formation of a wrought iron cake of mixed ferrous material and slag throughout the lower portion of the receptacle, and controlling such alteration of the relative positions of the slag bath and entering ferrous mate rial stream to prevent relative movement of such bath and entering stream substantially along a path previously traced by the stream on the surface of the bath until the ferrous material stream'has first been distributed over the major portion of the bath surface.

4. In a method of making wrought iron by pouring molten ferrous material into a bath of relatively cool slag in a receptacle, the steps comprising substantially continuously altering the relative positions of the slag bath and entering ferrous material stream to distribute the entering stream over the major portion of the bath surface to cause the formation of a wrought iron layer of mixed ferrous material'and slag on the lower portion of the receptacle, controlling such alteration of the relative positions of the slag bath and entering ferrous materialstream to form a second wrought iron layer of mixed ferrous material and slag superimposed on the first, and preventing relative movement of such bath and entering stream substantially along a path previously traced by the stream on the surface of the bath until the ferrous material stream has first been distributed over the major portion of the bath surface.

5. In a method of making wrought iron by pouring ferrous material into a slag bath, the step comprising altering the relative positions of the pouring stream and bath in more than one direction in such manner that the pouring stream as it. strikes the surface of the bath follows a non-retracing path.

6. In the manufacture of wrought iron, the steps comprising pouring the molten product ofa steel making process into a molten bath of slag, forming a welded wrought iron ball therein, and shifting the place of entry of the molten product into the slag bath by causing relative movement between the slag bath 7 and the molten product stream during the pouring operation in such manner that the molten product stream as it strikes the sur- 7 In a method of making wrought iron bypouring ferrous material from a ladle into a slag bath, the steps including shifting the relative positions of the ladle and bath transversely, changing their angular relation and tilting the ladle whereby the ferrous material stream traverses a continuous, intersecting but substantially non-retracing path on the surface of the slag bath.

8. In a method of making wrought iron by pouring ferrous material from a ladle into a slag bath, the step comprising altering the relative positions of the ladle and bath whereby the pouring stream traces a continuous and substantially non-overlapping path on the surface ofthe slag.

In testimony whereof I have hereunto set my hand.

. FREDRIK H. WILLE. 

